UNIVERSITI TEKNIKAL MALAYSIA MELAKA
EFFECT OF MIXING RATIO ON THE MECHANICAL
PROPERTIES OF POLYPROPYLENE COMPOSITE
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Process) (Hons.)
by
HAZWANI BINTI HILMI B050910129
901126-03-6112
FACULTY OF MANUFACTURING ENGINEERING
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Effect of Mixing Ratio on the Mechanical Properties of Polypropylene Composite
SESI PENGAJIAN: 2012/13
Saya HAZWANI BINTI HILMI
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
Lot 1388 Kg. Jias, Jln. Taliair, 17000 Pasir Mas,
DECLARATION
I hereby, declaredthis report entitled “Effect of Mixing Ratio on Mechanical
Properties of Polypropylene Composite” is the results of my own research except
as cited in references.
Signature : ……….
Author’s Name : HAZWANI BINTI HILMI
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM
as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Process) (Hons.). The member of the supervisory
committee is as follow:
ABSTRAK
Projek ini memberi perhatian kepada kesan nisbah pencampuran di atas sifat
mekanik komposit polipropilena. Objektif eksperimen ini adalah untuk menyiasat
sifat-sifat mekanikal bahan menggunakan ujian tegangan. Eksperimen telah
dijalankan di Makmal Polimer dan Makmal Bahan yang terletak di Fakulti
Kejuruteraan Permbuatan, UTeM. Tiga nisbah kenaf gentian-PP komposit digunakan
ialah: 10%: 90%, 30%: 70% dan 50%: 50%. Bentuk spesimen yang digunakan
adalah berbentuk tetulang anjing. Mesin hot press telah digunakan untuk
menghasilkan komposit kenaf gentian-PP. Sifat-sifat mekanik kenaf gentian-PP
komposit dan polipropilena diperolehi dari ujian tegangan. Daripada kajian ini,
didapati bahawa modulus tegangan meningkat dengan peningkatan jumlah kenaf.
Walau bagaimanapun, polipropilena tulen menunjukkan nilai bacaan yang lebih
tinggi dalam kekuatan tegangan tetapi nilai bacaan yang rendah dalam modulus
tegangan berbanding komposit polipropilena. Di samping itu, pemanjangan pada
waktu patah untuk PP komposit (K10:0.610%, K10/1:1.033%, K10/3:1.233%,
K105:1.237%, K30:0.407%, K30/1:0.513%, K30/3:0.617%, K30/5:0.817%,
K50:0.200%, K50/1:0.407%, K50/3:0.407% and K50/5:0.510%) menunjukkan
keputusan lebih rendah daripada polipropilena tulen, 0.613%. Oleh itu, sampel PP
komposit dengan pengikat adalah lebih baik dalam kekuatan tegangan, modulus
tegangan dan pemanjangan pada waktu patah daripada mereka yang tidak
ABSTRACT
This project focuses on the effect of mixing ratio on the mechanical properties of
polypropylene composites. The objective of this experiment is to investigate the
mechanical properties of material using tensile test. The experiment was performed
at Polymer Laboratory and Materials Laboratory located in Faculty of Manufacturing
Engineering, UTeM. Three ratios of the kenaf fibre-PP composite were used: 10%:
90%, 30%:70% and 50%:50%. The shape of the specimen used was dog bone shape.
The hot pressing machine for producing kenaf fibre-PP composite samples was used.
The mechanical properties of kenaf fibre-PP composite and polypropylene were
obtained by tensile test. From this study, it is found that the tensile modulus increases
with increasing the kenaf loading. However, pure polypropylene shows higher
reading value in tensile strength but low reading value in tensile modulus compared
to polypropylene composite. Further, the elongation at break for PP composites
(K10:0.610%, K10/1:1.033%, K10/3:1.233%, K105:1.237%, K30:0.407%,
K30/1:0.513%, K30/3:0.617%, K30/5:0.817%, K50:0.200%, K50/1:0.407%,
K50/3:0.407% and K50/5:0.510%) shows lower results than pure polypropylene,
0.613%. Thus, the samples of PP composite with binder were better in tensile
DEDICATION
ACKNOWLEDGEMENT
First and foremost, I would like to express my deepest gratitude to my Project
Supervisor, Dr. Mohd Amran Bin Md. Ali, thank you for the guidance given
throughout this Final Year Project. His guidance, advice, encouragement, patient and
support given throughout this project were greatly appreciated. Besides, I would also
like to thanks to panels, Dr. Mohd. Hadzley Bin Abu Bakar and Dr. Raja Izamshah
Bin Raja Abdullah for their support and guidance. Not forgotten, all lectures and
technicians which involve during my completion of this project, their guidance and
encouragement in helping me achieving my training objectives shall be not forgotten.
I would also like to thank my friends and also staff for support, guidance and
cooperation through this training. Their views and tips are very useful. The whole
time together really brought us together to appreciate the true value of friendship and
respect of each other.
Last but not least, I would also like to thank to my parents for always support me and
give me the strength to finish up this industrial training. Thanks for their
TABLE OF CONTENT
List Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1: INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scopes of the Research 3
1.5 Organizational of the Report 4
CHAPTER 2: LITERATURE REVIEW 5
2.1 Engineering Materials 5
2.4.2 Natural Fibre Composites Applications 19
2.6 Polypropylene-graft-maleic anhydride 21
2.6 Hot Pressing 22
CHAPTER 3: METHADOLOGY 34
3.1 Introduction 34
3.2 Discussion and conformation on project title 36
3.3 Literature review on project title 36
3.4 Identify the material 36
3.5 Select the machine 38
3.5.1 Panalux Blender Machine 38
3.5.2 Vibratory-Sieve Shaker Machine 40
3.5.3 Particle Size Analyzer Machine 40
3.5.4 Hot Press Machine 42
3.5.5 Internal Mixer Machine 43
3.5.6 Shear Cutter Machine 44
3.5.7 Sample Cutter Machine 45
3.5.8 Universal Testing Machine 46
3.6 Indentify Ratio of Polypropylene Composite 48
3.7 Prepare Sample of PP-Composite 49
3.7.1 Procedure of Compounding Process 50
3.7.2 Procedure of Hot Pressing Process 52
3.8 Test the Sample 54
3.9 Collect the Experiment Data 54
3.10 Analyzed the Data 55
3.11 Discussion, Conclusion and Recommendation 55
CHAPTER 4: RESULTS AND DISCUSSION 56
4.1 Stress Strain Graph 56
4.1.1 Tensile Strength 57
4.1.2 Tensile Modulus 60
4.1.3 Percentage of Elongation 65
4.2 Discussion 68
4.2.1 Tensile Strength 68
4.2.2 Tensile Modulus 71
CHAPTER 5: CONCLUSION AND RECOMMENDATION 75
5.1 Conclusion 75
5.2 Recommendation 76
REFERENCES 77
APPENDICES
A Table of Gantt chart for PSM1
B Table of Gantt chart for PSM2
C Stress Strain Graph of PP Samples
D Stress Strain Graph of K10 Ratio
E Stress Strain Graph of K10/1 Ratio
F Stress Strain Graph of K10/3 Ratio
G Stress Strain Graph of K10/5 Ratio
H Stress Strain Graph of K30 Ratio
I Stress Strain Graph of K30/1 Ratio
J Stress Strain Graph of K30/3 Ratio
K Stress Strain Graph of K30/5 Ratio
L Stress Strain Graph of K50 Ratio
M Stress Strain Graph of K50/1 Ratio
N Stress Strain Graph of K50/3 Ratio
O Stress Strain Graph of K50/5 Ratio
LIST OF TABLES
2.1 Sample formulations of kenaf and PP compositions 9
2.2 Properties of polypropylene 15
2.2 Comparison of flexural properties of commercial available
formaldehyde-based wood composites with data on-85% filled
kenaf-PP composite
38
3.1 Ratio of Polypropylene Composite 48
3.2 Ratio of PP composite in gram 49
4.1 Tensile Strength of PP and PP composites 60
4.2 Tensile Modulus of PP and PP composites 65
LIST OF FIGURES
2.1 Classification of engineering materials 6
2.2 Bar chart of room temperature stiffness (i.e., elastic modulus)
values for various metals, ceramic, polymers, and composite
materials
13
2.3 Bar chart of room temperature strength (i.e., tensile strength)
values for various metals, ceramics, polymers, and composite
materials
13
2.4 Bar chart of room temperature resistance to fracture (i.e.,
fracture toughness) for various metals, ceramics, polymers, and
composite materials
14
2.5 Kenaf trees 18
2.6 Kenaf’s part 18
2.7 Natural Fibre Polymer Sheets 20
2.8 Application of Natural Fibre Polymer 21
2.9 Others Application of Natural Fibre Polymer 21
2.10 Hot Press Machine 22
2.11 Graph of stress vs strain 24
2.12(a) A standard tensile-test specimen before and after pulling,
showing original and final gage lengths
25
2.12(b) Stages in specimen behaviour in a tension test 26
2.13 A typical stress-strain curve obtained from a tension test,
showing various features
27
2.14 Effect of Kenaf-PP Composition on Tensile Strength 28
2.15 Possible Schematic of Epolene 43 Treated Kenaf-PP
Composites
29
2.16 The SEM Micrograph of Epolene 43 Kenaf Treated Sample 29
eco-core with journal
3.1 Flow Chart of Methadology 34
3.2 Kenaf fibre 37
3.3 Polypropylene (PP) 37
3.4 Polypropylene-graft-maleic anhydride 37
3.5 Kenaf fibre that was being cut 38
3.6 Panalux Blender Machine 39
3.7 Blend of Kenaf Fibre 39
3.8 Vibratory sieve-shaker machine 40
3.9 Kenaf fibre taken to analyze 41
3.10 Particle Size Analyzer Machine 41
3.11 Mastersizer 2000 software 42
3.12 Hot Press machine 43
3.13 Internal mixing machine 44
3.14 Shear cutter machine 44
3.15 Sample cutter machine 45
3.16 Dog bone shape samples 45
3.17 Universal Testing machine 46
3.18 Tensile Testing of Sample 47
3.19 Trapezium software 47
3.20 Schematic flow diagram of polypropylene composite 50
3.21 File created in HAAKE PolySoft OS 51
3.22 Temperature and speed of internal mixer machine 52
3.23 Set temperature on hot press machine 53
3.24 Compound in hot press mould 53
3.25 Dimension of sample 54
4.1 Stress Strain graph (K10/0 sample) 56
4.2 Tensile test data of K10 (sample 1) ratio 57
4.3 Tensile test data of K10 (sample 2) ratio 58
4.5 Stress strain graph of PP (sample 1) 61
4.6 Stress strain graph of PP (sample 2) 62
4.7 Stress strain graph of PP (sample 3) 63
4.8 Effect of PP, Kenaf-PP Composition on Tensile Strength 68
4.9 Possible Schematic of Epolene 43 Treated Kenaf-PP
Composites
69
4.10 Tensile strength results done by Saad, M. J. (2011) in his study 70
4.11 Effect of PP and Kenaf-PP Composition on Tensile Modulus 71
4.12 Tensile Modulus results done by Saad, M. J. (2011) in his study 72
4.13 Effect of PP, Kenaf-PP Composition on Elongation at Break 73
4.14 Elongation at Break results done by Saad, M. J. (2011) in his
study
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
Ao - Cross-sectional area
ASTM - American Standard Testing Material
EFB - Empty Fruit Bunch fibre
g - Gram
KFRP - Kenaf fibre reinforced polypropylene
K-PP - Kenaf fibre-Polypropylene
l - Length
Lf - Final gauge length
Lo - Original gauge length
MAPP - Maleated polypropylene
mm - Milimeter
MPa - Megapascals
P - Load
PP - Polypropylene
RIM - Reaction injection molding
SEM - Scanning electron microscopy
Tg - Glass-transition temperature
UTeM - University Technical Malaysia, Malacca
UTS - Ultimate Tensile Strength
Wf - Fibre weight
σ - Stress
e - Strain
REFERENCES
Ashby, Micheal F. (2011). "Materials Selection in Mechanical Design".4th Ed.
United States: Elsevier Ltd.
Atefi, R., Razmavar, A., Teimoori, Farhad Teimoori, Farshad. (2012)."Investigation
on New Eco-Core Metal Matrix Composite Sandwich Structure".Life Science
Journal.
Callister, William D., Rethwisch, David G. (2011). "Materials Science and
Engineering".8th Ed. Asia: John Wiley & Sons (Asia) Pte Ltd.
Everise Crimson (M) Sdn Bhd. "What is Kenaf". [Online].Available
at:http://www.kenaf-everise.com.my/Kenaf_Everise/What_is_Kenaf.html (Accessed:
24 November 2012).
G. S. Upadhyaya. (1997)."Powder Netallurgy Tehnology". England: Cambridge
International Science Publishing.
G. Taguchi. (1998)."Introduction to Quality Engineering: Designing Quality into
Product and Process". Asian Productivity Organisation, Japan.
Granta's CES Edupack. (2007).Granta Material Intellingence. Granat Design Limited
2007.
Kalpakjian, Serope.,Schmid, Steven R.,Musa,Hamidon.(2010)."Manufacturing
Engineering and Technology" (6th Ed).Singapore: Prentice Hall.
Noor Aliah Nordin.(2008). "Design and Analysis of Sandwich Beam make by
Combination of Kenaf Core and Bast". Degree of Bachelor of Engineering (Honours)
Manufacturing (Material Engineering), University Technical Malaysia Melaka
(UTeM).
Onder, A.(2007). "First Failure Pressure of Composite Pressure Vassels".M.Sc
Thesis, Graduate School of Natural and Applied Sciences of Dokuz Eylül
University.
Polycomposite Sdn. Bhd.. [Online]. Available at: http://www.polycomposite-sb.com
(Accessed: 20 May 2013).
Poly Group Inc. [Online]. Available at: http://www.polygroupinc.com (Accessed: 11
June 2013).
Richardson and Lokensgard.(1997)."Industrial plastic theory and applications". 3rd
Ed.Singapore: Delmar Publisher Inc. pp. 143-146.
Saad, M. J. (2011)."Effect of Maleated Polypropylene (MAPP) on the Tensile, Impact
and Thickness Swelling Properties of Kenaf Core–Polypropylene Composites".
CHAPTER 1
INTRODUCTION
Chapter 1 describes the introduction of the project. In this project, the effect of
mixing ratio on the mechanical properties of polypropylene composite is studied.
This chapter includes the background, problem statement, objectives and the scope of
this project.
1.1 Background
Nowadays, various composites made from natural fibre are commercialized. The
natural fibres are widely used as the reinforcement in making composites. The
natural fibres have their advantages which they are low cost, lightweight, easy to find
and high strength to weight ratio. Therefore, the demand of natural fiber in the
manufacturing industry is increasing. It is because lack of sources and the increasing
construction materials which based on mineral sources such as steel, aluminium and
forest trees.
This project focuses on the effect of mixing ratio on the mechanical properties of
polypropylene composites. The purpose of this project is to find out the mechanical
properties of polypropylene composite and pure polypropylene using Tensile Test.
Thus, the results obtained can be extracted and analyzed. Compounds of the
polypropylene composites are mixed with different mixing ratio. Therefore, the
The materials used in this project were Polypropylene (PP) and Kenaf fibre. To
ensure mixing ratios between kenaf fibre and PP are fully mixing, coupling agent
Polypropylene-graft-maleic anhydride (MAPP) was used.
In this project, polypropylene composite sample mixed between Kenaf
fibre-Polypropylene (K-PP) composites were employed. The polypropylene composite
samples were prepared by hot press machine. The results obtained from the tensile
test was compared with polypropylene composites and the pure polypropylene which
the differences can be seen clearly.
1.2 Problem statements
The mixing ratio can affect the mechanical properties of composite. Thus, this
project was carried out to study the effect of the mixing ratio on the mechanical
properties of the polypropylene composite. Tensile test was carried out in order to
obtain the mechanical properties of the polypropylene composite. The project has
been carried out in the Polymer Laboratory which is in University Technical
Malaysia Malacca (UTeM) at Durian Tunggal, Melaka. The laboratory is equipped
with an mixer machine, hot press machine and sample cutter machine. For the tensile
test, it was conducted at the Materials Laboratory which in UTeM. The materials
laboratory is equipped with a Universal Testing machine to conduct the mechanical
1.3 Objectives
The aim of this project is to study the effect of mixing ratio on the mechanical
properties of polypropylene composite. The main objectives are:
1. To prepare polypropylene composite samples that are different in mixing
ratio.
2. To find out the mechanical properties of material using tensile test.
3. To compare on mechanical properties of polypropylene composite.
4. To compare on mechanical properties of pure polypropylene and
polypropylene composite.
1.4 Scopes of the research
This project focuses on the effect of mixing ratio on the mechanical properties of
polypropylene composites. In this project, only one natural fiber uses that is kenaf
fibre. The machines that used in this project were hot press machine, blender,
vibratory sieve-shaker machine, universal testing machine, mixer machine and
sample cutter machine. Three ratios of the kenaf fibre-PP composite used were: 10%:
90%, 30%:70% and 50%:50%. The polypropylene composite that is made in this
project is kenaf fibre-polypropylene (K-PP). The mechanical properties that observed
in this project was tensile test. The shape of the specimen is dog bone shape or so
1.5 Organizational of the report
To keep close the aim and objectives of this study, this report is organized in five chapters as follows:
• Chapter 1–provides background and gist of the study.
• Chapter 2–presents literature review of composites, natural fibre and testing.
• Chapter 3–gives information on materials, testing procedures that involve in the experiment.
• Chapter 4–reports on the results and discussion of experimental works.
This section basically shows the analysis of relevant journal, book and testing
standard to the case study purpose. In this chapter, it contains few sections which
are introduction to engineering materials, composites, polymer, natural fibres,
hot press machine and tensile test.
2.1 Engineering Materials
Ashby et al. (2011) state that the engineering materials can be classified into the six
broad families as show in Figure 2.1. Six broad families of engineering materials are
metals, polymers, elastomers, ceramics, glasses, and hybrids. The members of a
family have certain features in common: similar properties, similar processing routes,
and, often, similar applications. The hybrids are the combinations of two or more
materials in predetermined configuration and scale. They combine the attractive
properties of the other families of materials while avoiding some of their drawbacks.
The family of hybrids includes fibre and particulate composites, sandwich structures,
lattice structures, foams, cables, and laminates: almost all the materials of nature –
wood, bone, skin, and leaf –are hybrids. Fibre-reinforced composites are, of course,
the most familiar. Most of those at present available to the engineer have a polymer
matrix reinforced by fibres of glass, carbon, or Kevlar (an aramid). They are light,
stiff, and strong, and can be tough.
Figure 2.1:
According Ashby et
high elastic moduli. Most
made strong by alloy
ductile, allowing them
alloys (spring steel, f
enough to ensure that
occurs, is of a tough,
to fatigue and of all the
Ceramics, too, have hi
in tension means the b
strength, which is about
they have a low tolera
contact stresses (at cla
Glasses are noncrysta
lime and borosilicate
.1: Figure classification of engineering materials (Ashby
et al. (2011), it states that metals are stiff. Th
i. Most, when pure, are soft and easily defor
lloying and by mechanical and heat treatment
hem to be formed by deformation processes. Ce
l, for instance) have ductilities as low as 1%
hat the material yields before it fractures and tha
h, ductile types. Partly because of their ductili
l the classes of material. They are the least resist
ve high moduli, but unlike metal, they are brittl
he brittle fracture strength; in compression it is t
about 15 times greater. And because ceramics
olerance for stress concentrations (like holes or c
clamping point, for instance).
stalline (“amorphous”) solids. The most comm
ate glasses familiar as bottle and ovenware, but by 2011).
They have relatively
formed. They can be
ent, but they remain
s. Certain high-strength
1%, but even this is
nd that fracture, when it
tility, metals are prey
sistant to corrosion.
ittle. Their “strength”
is the brittle crushing
ics have no ductility,
or cracks) or for
high-ommon are the soda –
